Viessmann VITOSOL-F Operating instructions

Service instructions
for contractors
VIESMANN
Vitosol-F
For applicability, see the last page
VITOSOL-F
5692 887 GB 8/2010 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system
■ National installation requirements
■ All legal instructions regarding the pre-
vention of accidents,
■ All legal instructions regarding envi-
ronmental protection,
■ The Code of Practice of relevant trade
associations
■ All current safety regulations as
defined by DIN, EN, DVGW, VDE and
all locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI and SWKI
Working on the system
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing the separate fuse or
by means of a main isolator.
Note
In addition to the control circuit, there
may be several power circuits.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electrostatic dis-
charges.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Replace faulty components only
with original Viessmann spare
parts.
Safety instructions
Safety instructions
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Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
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Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 6
Scope of inspection........................................................................................... 14
Parts lists
Parts list................................................................................................................ 15
Specification
Vitosol 200-F........................................................................................................ 17
Vitosol 300-F........................................................................................................ 17
Certificates
Declaration of conformity...................................................................................... 18
Index
Index
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Checking pressure conditions and pre-charge
pressure............................................................................. 6
••• 2. Checking the function of the safety equipment
••• 3. Checking electrical connections..................................... 7
•4. Flushing, testing for leaks and filling the solar thermal
system............................................................................... 8
••• 5. Determining the flow rate and adjusting if required...... 11
• • 6. Starting the system.......................................................... 12
••• 7. Checking the switching function of the solar control
unit..................................................................................... 12
• • 8. Checking heat transfer medium and replacing if
required............................................................................. 12
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Checking pressure conditions and pre-charge pressure
Cover the collectors.
Note
The glass cover of Viessmann flat-plate
collectors is coated with a protective
foil.
For vacuum tube collectors, use the tar-
paulins available as accessories.
Before the solar thermal system is
flushed or filled, check the pre-charge
pressure of the expansion vessel. This is
no longer possible once the solar ther-
mal system is operational.
Note
A manual pressure gauge can be found
in the solar service case available as an
accessory.
Enter values into the following table.
These can be retained for later inspec-
tion and maintenance work on the solar
thermal system.
P
5
1
3
2
4
Commissioning, inspection, maintenance
Further details regarding the individual steps
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Documentation of pressure
1System pressure of the solar thermal system 1 bar
2Supplement per metre static ceiling + 0.1 bar/m
3System operating pressure (pressure gauge)
................ bar
Pressure reserve for venting + 0.1 bar
Filling pressure
................ bar
4Supplement per metre of height difference between pres-
sure gauge — expansion vessel 5
+ 0.1 bar/m
Deduction for hydraulic seal – 0.3 bar
Pre-charge pressure, expansion vessel 5
................ bar
Note
Note the pre-charge pressure level on
the expansion vessel. In doing so, spe-
cifically use the term "pre-charge pres-
sure" to prevent misunderstandings.
Example:
At 10 m static ceiling, the result is:
■ System operating pressure = 2 bar
■ Fill pressure = 2.1 bar
■ Pre-charge pressure = 1.7 bar
Checking electrical connections
Check the tightness of the electrical
plug-in connectors and cable grommets;
check cables for damage.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Flushing, testing for leaks and filling the solar thermal system
■
!Please note
Filling and commissioning the
solar thermal system without
first safeguarding heat transfer
results in thermal loads.
If commissioning is carried out
prior to this, cover the collec-
tors and keep covered until
heat transfer has been regula-
ted.
Note
The glass cover of Viessmann flat-
plate collectors is coated with a pro-
tective foil.
For vacuum tube collectors, use the
tarpaulins available as accessories.
■ Flushing the solar thermal system
– Soldered copper pipes
Flush particularly thoroughly as any
residual scale may damage the
operation of the solar thermal sys-
tem.
– Flush solar thermal system with heat
transfer medium. Otherwise there is
a risk that residual water from flush-
ing may become mixed with the heat
transfer medium and thus alter its
properties.
Note
To flush and fill the solar thermal
system, use the filling container or
filling station available as acces-
sories. These contain high speed
pumps with high pump rates and fil-
ters.
■Never drain the system with a suction
pump.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Solar-Divicon (accessory)
0
20
40
60
80
100
120 0
20
40
60
80
100
120
2
4
6
8
10
12
L/Min
BA
D
C
AThermometer/non-return valve,
flow
BThermometer/non-return valve,
return
CSafety assembly, with 6 bar safety
valve
DFlow indicator
Fill valve (accessory)
E
F
EShut-off tap
FDrain & fill taps
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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P
A
B
C
D
APressure gauge
BDrain & fill taps
CContainer for heat transfer medium
DShut-off valve
1. Open shut-off taps or valves. With the
Solar-Divicon, open the non-return
valves by turning the thermometers
clockwise through 45° (see diagram
on page 9).
2. Close shut-off tap E; open drain &
fill taps F on the fill valve (see dia-
gram on page 9).
Connect hoses from the flushing and
filling facility. Fill the container with
heat transfer medium.
Note
Flush the system via the return con-
nection (flow direction to the collec-
tor).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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3. Use a high speed pump to flush the
system. Observe the fluid level in the
container and top up with heat trans-
fer medium if necessary to prevent
any air entering the solar circuit. Let
the fill pump run until no more air bub-
bles rise to the top of the container.
4. Close the drain tap on the fill valve
and let the fill pump run until the
required system pressure is reached
(including 0.1 bar pressure reserve
for residual ventilation during opera-
tion).
Notes on residual ventilation
Even after thorough ventilation, some
dissolved air will still remain in the
heat transfer medium. This will be
released as the temperature rises,
and will be extracted via the air sep-
arator.
5. Close the fill tap on the fill valve; open
the fill pump.
Pressure must not drop for at least 30
minutes.
6. Vent the circulation pumps. Select
manual mode.
Repeat the ventilation process until
the float in the flow indicator of the
Solar-Divicon (see diagram on
page 9) holds a constant position
when the pump is running.
Note
Air can be recognised in the flow indi-
cator (float moves).
Determining the flow rate and adjusting if required
Read off the value at the bottom edge of
the float in the flow indicator of the Solar-
Divicon (see diagram on page 9).
In conjunction with multi stage circulation
pumps, set the required flow rate via the
output stage (see the following table for
approximate set values).
Adjustable flow rates
The details in the following tables do not take the pipe pressure drop into account.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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High flow operation, 40 l/(h·m2)
Number of
collectors
Flow rate in l/min
2 3
3 4.5
4 6
5 7.5
6 9.5
7 10.5
8 12.5
9 14
10 15.5
11 17
12 18.5
13 20
14 21.5
15 23.5
Low flow operation, 15 l/(h·m2)
Number of
collectors
Flow rate in l/min
6 3.5
7 4
8 4.5
9 5
10 5.5
11 6.5
12 7
13 7.5
14 8
15 8.5
16 9
18 10.5
20 11.5
Vitosol 200-F, type 5DIA
Throughput 5 to 6 l/min
Starting the system
Close the air vent valve. Observe operating instructions of
installed components.
Checking the switching function of the solar control unit
Solar control unit installation and
service instructions
Checking heat transfer medium and replacing if required
The heat transfer medium provided is a
liquid based on 1,2-propylene glycol with
a pH value of 9.0 to 10.5 and frost pro-
tection down to −28 °C.
Monitor the operating condition of the
medium as part of the annual service of
the solar thermal system by the heating
contractor.
With the solar service case (acces-
sory), the pH value and frost protection
temperature can be checked.
In some cases the manufacturer of the
heat transfer medium can carry out a
laboratory test of the medium, subject to
arrangement.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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TYFOROP CHEMIE GmbH
Anton-Rée-Weg 7
D - 20537 Hamburg
e-mail: [email protected]
Internet: www.tyfo.de
1. Check the pH value of the heat trans-
fer medium using the pH strip in the
solar service case (accessory).
The colour of the pH strip indicates
the approximate value. If the value is
below 7.5, replace the heat transfer
medium.
Notes on replacing the heat trans-
fer medium
The heat transfer medium can only
be mixed with Tyfocor G-LS.
Never mix with water or third party
media.
2. Check the frost protection tempera-
ture of the heat transfer medium with
a Viessmann antifreeze tester or the
manual refractometer in the solar
service case.
Solar service case operating
instructions
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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The solar thermal system should be
inspected once a year to ensure opera-
tional reliability.
In addition to this, a visual check of all
essential components (e.g. collectors
and pipework) is recommended every 3
to 5 years.
■ Vent the solar thermal system.
■ Compare system operating pressure
with the set value. If the values are dif-
ferent, check the expansion vessel.
■ Check heat transfer medium.
■ Start circulation pumps manually if
necessary (listen for noises).
■ Compare flow rate with set value.
■ Check thermostatic mixing valve is
moving easily (if installed).
■ Check plausibility of the solar param-
eters subject to the solar radiation (e.g.
flow and return temperatures at the
thermometers; collector and cylinder
temperatures at the solar control unit).
The safety valve does not have to be
checked if there are no visible signs of
activation (e.g. deposits, drips).
Scope of inspection
Scope of inspection
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When ordering spare parts:
Quote the part and serial numbers (see
type plate) and the position number of
the required part (as per this parts list).
Obtain standard parts from your local
supplier.
Parts
001 Connection pipe
002 Connection pipe (short)
003 Connection pipe (long)
004 Plug
005 Locking ring fitting with support
sleeves
006 Elbow fitting with support sleeves
007 Clamping bracket, complete
008 Connecting part
009 Mounting bracket
012 O-ring
014 Profile clip
015 Diagonal sealing strip
016 Support sleeve
030 Collector retainer with screws
031 Sealing material
033 Air vent plug
034 Cross union with support sleeve
035 Repair panel
037 Fixing clamp
Parts not shown
020 Special valve grease
021 Dismantling instructions
022 Operating instructions
023 Service instructions
025 Installation instructions for pitched
roofs, above roof installation with
roof hooks
026 Installation instructions for pitched
roofs, above roof installation with
rafter anchors
027 Installation instructions for flat roofs
or freestanding installation
028 Installation instructions for roof
integration
029 Sealing screws (5.5 x 20; 6 x 42)
032 Bit holder
036 Wood screws, 8 x 120 (5 pce)
Parts lists
Parts list
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001 002 003 004
005 006 007
008 009
014
012
015 016
034031 035 037
030
033
Parts lists
Parts list (cont.)
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Type SV2A/
SH2A
SV2B/
SH2B
5DIA
Absorber area m22.32 2.32 4.76
Aperture area m22.33 2.33 4.96
Thermal capacity c kJ/(m2·K) 5.0 4.6 6.40
Max. idle temperature °C 186 185 200
Permiss. operating pres-
sure
bar 6 6 6
Content, heat transfer
medium
litres 1.83/2.48 1.83/2.48 3.34
Vitosol 300-F
Type SV3A/SH3A SV3B/SH3B
Absorber area m22.32 2.32
Aperture area m22.33 2.33
Thermal capacity c kJ/(m2·K) 5.0/4.6 4.6
Max. idle temperature °C 206 205
Permiss. operating pressure bar 6 6
Content, heat transfer medium litres 1.83/2.48 1.83/2.48
Specification
Vitosol 200-F
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We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, declare as sole respon-
sible body, that the product
Vitosol-F
conforms to the following standards:
DIN 1055
EN 12975 to solar KEYMARK
In accordance with the following directives, these products are designated _:
2006/95/EC
2004/108/EC
97/23/EC
Details according to the Pressure Equipment Directive (97/23/EC):
■ Heated pressure equipment
■ Class I according to appendix II, diagram 5
■ Module A according to appendix III
■ Identification of individual devices with a content of less than 2 litres as an assembly
according to article 3 (2), subject to the installation of at least one pair
The pressure device was tested without fitted equipment (safety assembly).
The pressure device must be equipped in accordance with current national regula-
tions prior to installation and commissioning.
For the energy assessment required by the EnEV of heating and ventilation equip-
ment to DIN V 4701-10, when determining system values for the product Vitosol, the
product characteristics calculated as part of EC type testing according to the
Efficiency Directive can be used (see specification table).
Allendorf, 1 August 2010 Viessmann Werke GmbH&Co KG
pp. Manfred Sommer
Certificates
Declaration of conformity
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Applicability
Applicable to the following col-
lectors:
Vitosol 200-F, type 5DIA Part no. 7439 235
Vitosol 200-F, type SV2A Part no. 7374 162
Vitosol 200-F, type SH2A Part no. 7374 161
Vitosol 200-F, type SV2B Part no. 7417 763
Vitosol 200-F, type SH2B Part no. 7417 764
Vitosol 300-F, type SV3A Part no. 7374 164
Vitosol 300-F, type SH3A Part no. 7374 163
Vitosol 300-F, type SV3B Part no. 7417 765
Vitosol 300-F, type SH3B Part no. 7417 766
Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Viessmann Werke GmbH&Co KG
D-35107 Allendorf
Telephone: [phone]
Fax: [phone]
www.viessmann.com
5692 887 GB Subject to technical modifications.
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